Louvered echelon lens

ABSTRACT

Louvered echelon lenses are provided that comprise an optically clear layer having at least one of its large-area surfaces configured as a set of echelon lens elements, and physically attached in optical connection with said layer, an internally louvered layer that comprises an optically clear polymeric matrix and a set of thin optically limiting louvers supported within the matrix in a spaced side-by-side relation.

INTRODUCTION

Echelon lenses comprising polymeric sheets having at least one of theirlarge-area surfaces configured as a set of echelon lens elements areuseful to enhance a variety of diplays of graphic information. Forexample, such echelon lenses may be placed over a matrix oflight-emitting diodes to enlarge the symbols that are displayed on thematrix. Similarly, the lenses may be used to enlarge a display ofinformation on a nematic liquid crystal device, to enlarge images on acathode ray tube, or to enlarge an image projected from the rear onto apanel or screen.

While the use of an echelon lens in the described manner offerssignificant advantages in itself, it has now been found that a uniqueechelon lens construction provides even better results. This uniqueconstruction overcomes a problem inherent in an echelon lens, namely alack of contrast between an image focused by the lens and the lensitself. This lack of contrast arises because a portion of the light rayspassing through the lens are reflected within the lens by the facets ofthe linear lens elements, with the result that light rays emanate fromthe whole surface of the lens. These internally reflected light raysprovide a background for the focused image, which is accordingly lessdistinct than it would be if there were no internal reflections.

The present invention improves the contrast of an echelon lens by use ofan internally louvered layer superposed over the echelon lens elements.It has been found that by superposing the louvered layer -- whichcomprises a set of optically limiting louvers supported in spacedside-by-side relation in an optically clear polymeric matrix -- in closeproximity to an optically clear layer configured as the echelon lenselements, the louvers reduce the internal reflections of the lenselements and increase contrast.

Further, the invention achieves this improvement in contrast withoutintroducing undesired moire patterns that normally occur uponsuperpositioning of two grids or networks of closely spaced lines. Suchmoire patterns are very noticeable when a typical fresnel lens, such asthe condensing lens used in an ovehead projector having a large-diameterset of concentric annular echelon lens elements, is superposed in closeproximity over an internally louvered layer. At worst, such moirepatterns would seriously interfere with a message being presented by agraphic display, and at best they would be distracting, often to thepoint of commercial unacceptability.

By using echelon lens elements superposed in proper alignment overlayers containing linear louvers, preferred lenses of the inventionreduce moire patterns to such a fine grain that they are not detected byhuman vision. For example, by arranging the linear louvers at rightangles to linear echelon elements, there is only point-type overlap ofthe louvers and echelon lens elements, with the result that no moirepatterns are seen by a viewer. Further, by using two superposed linearechelon lenses, with the linear echelon lens elements at right angles toone another, and with an internally louvered layer between the twolenses aligned so that the louvers are at 45° to the linear echelon lenselements of both lenses, a louvered echelon lens is obtained that iscapable of two-axis or point focusing but does not exhibit detectablemoire patterns. The resulting lens effectively focuses like a fresnellens having concentric annular lens elements, and it can be made inlarge diameter sizes without causing the distracting moire patterns thatoccur upon use of an internally louvered layer and a typicallarge-diameter fresnel lens.

SUMMARY OF THE INVENTION

Briefly, a lens of the invention, which for purposes herein will bedescribed as a louvered echelon lens, comprises,

1. an optically clear layer having at least one of its large-areasurfaces configured as a plurality of echelon lens elements that directlight rays transmitted through the layer in a predetermined manner, and

2. physically united in optical connection with said layer, aninternally louvered sheet comprising an optically clear polymeric matrixand a set of thin optically limiting linear louvers supported within thematrix in spaced side-by-side relation, with each louver being set at anangle to the faces of the sheet.

(By the term "echelon lens" it is meant a structure that includes aplurality of echelon lens elements. These echelon lens elements maycooperate to direct light rays toward one or more focuses, or they maydirect light rays in other ways, as when all the echelon lens elementshave the same configuration and refract incident light rays to the samedegree. A lens of the invention may also comprise an array of individuallenses. For example, a lens of the invention may include several groupsof annular echelon lens elements; each group is usually concentric abouta different axis, but may be concentric about the same axis, as wheneach different group cooperates to direct light rays to a differentfocus. The term array is also applied to a lens that comprises linearechelon lens elements that cooperate to direct light rays to a singlelinear focus, since different sections or portions along the length ofthe lens may be used to direct light rays from different light sources,as from different portions of a matrix of light-emitting diodes; in suchsituations each section may be regarded as an individual lens. The termlens is also used to include both optical elements in which light raysenter on one side and leave from the other side and optical elementsthat carry a reflective layer, so that light rays enter on one side,travel through the lens and are then reflected back through the side ofentry; see FIG. 12.)

Because preferred lenses of the invention are flexible, a largecontinuous roll of lens stock may be prepared, with an array ofindividual lenses arranged along the length of the stock. A lens of theinvention may be prepared by cutting a length from the lens stock whichincludes one or more individual lenses.

Usually the louvers in a lens of the invention are normal to the facesof the internally louvered layer. However, they may be tilted at otherangles, and may even be tilted at angles that differ from louver tolouver, as when a set of louvers is fanned so as to more closelyparallel, and thus permit passage of, the rays emanating from a pointsource.

The improvement in contrast provided by a lens of the invention can beseen by placing a conventional linear echelon lens over one portion ofan image-displaying lighted matrix of light-emitting diodes, and alouvered linear echelon lens of the invention over a different portionof the lighted matrix. A sharper contrast between image and backgroundwill be seen through the louvered linear echelon lens than through theconventional lens. Even if the image seen through the louvered lens isless bright, the improvement in contrast will make the image more easilyread.

Besides improving contrast by reducing internal reflections, a louveredechelon lens of the invention also minimizes lighting of a lens surfaceby extraneous light, such as light intended to illuminate an adjacentlens. For example, when a lens of the invention comprising an array ofside-by-side individual lenses is placed over a matrix of light-emittingdiodes, each individual lens of the invention is generally unaffected byan adjacent portion of the matrix of light-emitting diodes. Further,images provided by lenses of the invention can be seen better out-doorsin bright sunlight than can the images presented by a conventional lens,which may be completely obliterated by bright sunlight.

Lenses of the invention also are useful to take the place of fannedlouvered films, as described above, in which louvers are tilted atangles that differ from louver to louver. Such fanned louvered films aredifficult to make, but by constructions of the invention such fanning isachieved by refraction of light rays with lens elements.

BACKGROUND TEACHINGS

Internally louvered sheets of the kind useful in the present inventionare taught in U.S. Pat. Re. No. 27,617. These sheets or films areconveniently made by skiving a continuous web from a cylindrical billetthat has been prepared by compressing an assembly of alternate circularlayers of clear polymeric material and black or other opaque ortransparent colored layers. To improve the clarity of the product, clearfilms, preferably of the same polymer as the clear layers of the billet,may be laminated or coated on each side of the skived web.

Internally louvered sheets have previously been used in combination withechelon lenses, but these previous uses have been for purposes differentfrom purposes or objects of the present invention, and these previoususes did not involve a discovery of the improved contrast and otheradvantages associated with the present invention. For example, Erwin,U.S. Pat. No. 3,511,563, describes overhead projectors which use alouvered film between the stage of the projector on which transparenciesbearing an image to be projected are laid and an annular fresnelcondensing lens through which the projection lamp is beamed. Such a useof a louvered film is found to limit glare from the lamp that wouldotherwise be seen by a person using the projector, who normally standsadjacent the projector so as to be able to point to portions of theprojected image, to change transparencies, etc.

In the course of the Erwin patent, it is mentioned that the louveredfilm and fresnel lens can be incorporated into an integral structure.However, the structures suggested in the patent are different from thoseof the present invention -- the structures of the patent would be largerigid structures combining concentric annular echelon lens elements andlouvered film to give rise to disconcerting moire patterns --, and theyrepresent different discoveries -- as illustrated by the fact that inthe projector the louvers prevent glare to a user who is off the opticalaxis of the projector, while the present invention improves visibilityfor a viewer who is on the optical path. In the projector the louverswere a direct shield, whereas in the present invention, the louversmodify the characteristics of a lens.

Louvered films have also been used with planar transparent sheets in adisplay device that carries an image on the transparent sheet. In thisway ambient light, either in back of, or in front of, the transparentsheet is shielded so as to darken the background, which could otherwiseobliterate the image. The present invention is distinctive from suchprior uses in that the structure combined with a louvered layeraccording to the invention has a configured surface, and the combinationis found to reduce reflections that arise internally within thestructure because of the configurations. A structure of the inventionthus improves contrast between the image and background as transmittedby the lens, but does it without causing disconcerting moire patterns.

All in all, the present invention provides an important improvement formany uses of echelon lenses by making the images transmitted by suchlenses more clear and distinctive.

DESCRIPTION OF THE DRAWINGS

FIGS. 1-4 are enlarged end views through illustrative louvered echelonlenses of the invention;

FIGS. 5 and 6 are enlarged top schematic views of louvered linearechelon lenses of the invention;

FIG. 7 is an enlarged top schematic view of a lens of the invention thatcomprises a longitudinally extending array of louvered annular lenses;

FIG. 8 is an enlarged cross-section through the lens of FIG. 7;

FIGS. 9 and 10 are schematic views illustrating how moire patterns arereduced in louvered annular lenses of the invention;

FIG. 11 is an enlarged exploded view of a lens of the invention thatincludes two orthogonally superposed linear echelon lenses and aninternally louvered layer; and

FIG. 12 is a reflective louvered echelon lens of the invention.

DETAILED DESCRIPTION

An illustrative louvered echelon lens of the invention 10 is shown inenlarged cross-section in FIG. 1. This lens 10 comprises an internallylouvered web 11, comprising clear polymeric matrix portions 12 andopaque layers 13, which may consist of polymeric material pigmented withcarbon black, for example. An optically clear film, 14, preferably ofthe same material as the portions 12, is laminated to the bottom side ofthe internally louvered web 11, and a configured, optically clear layer15, which is also preferably of the same material as the portions 12, islaminated to the top side of the internally louvered layer 11. Theconfigurations 16 on the layer 15 are linear echelons lens elements thatcooperate to direct light rays 17 transmitted through the sheet toward alinear focus 18.

A useful method for making a louvered lens as shown in FIG. 1 is tofirst prepare the internally louvered web or sheet 11 (as by skivingfrom a layered billet); then assemble preformed films of a desiredpolymer on each side of the internally louvered web; and then place theassembly between two platens of a press, one of the platens having asmooth surface for engagement against the layer 14, and the other platenbeing configured to provide the linear lens elements 16. Uponapplication of heat and pressure, the preformed films become bonded tothe internally louvered layer 11 and the layer 15 is configured with thelinear lens elements 16. Alternatively the assembly of layers may bepassed between rollers, one roller being configured as an embossingroller and the other roller having a smooth surface. The three layerspreferably at least have the same index of refraction and morepreferably are of the same polymeric material; in the presence of heatand pressure the three layers become joined so that there is in effectno interface between the layers, at least none that has any significantoptical effect.

The construction shown in FIG. 1 is preferred, because it is more thin,therefore having less effect on transmitted light, and more flexible;because it requires less manufacturing steps; and because there are thefewest lines of juncture where potential optical interfaces could occur.However, louvered lenses of the invention may take other forms also.FIG. 2 shows a lens 20 such as results when a preformed louvered film 21of the type described in U.S. Pat. Re. No. 27,617, having opticallyclear layers 22 and 23 on each side of a skived web 24, is laminated toa configured layer 25. For purposes herein the preformed film 21 isregarded as a single internally louvered sheet, and under properconditions of manufacture, the lines of juncture between the layers 22and 23 and skived web 24 have no significant optical effect; a skivedweb 11 of the lens 10 shown in FIG. 1 is also regarded as a singleinternally louvered sheet.

In the embodiments illustrated in FIGS. 1 and 2, adhesion between theconfigured optically clear layer and the internally louvered sheet isachieved directly by the heat and pressure of a laminating and embossingoperation. The configured layer and louvered sheet are united in otherways in less preferred embodiments of the invention. A layer of adhesivematerial, which is preferably of the same index of refraction as theother layers of a lens of the invention, and which may be applied insolution, as a hot-melt, or as a liquid curable material, is usedbetween the configured layer and louvered sheet in some embodiments ofthe invention. Interconnectors, such as linear projections that engagein linear grooves, are also useful and permit the use of inwardly facingechelon lens elements.

The latter kind of arrangement is illustrated in FIGS. 3 and 4. FIG. 3shows, in exploded form, the components of lens 30 of the invention inwhich a first composite sheet 31 comprising a skived louvered web 32, abottom clear layer 33, and a configured top layer 34 having linear lenselements 35 and linear grooves 36 is attached to a second compositesheet 37 configured with linear lens elements 38 and linear projections39 which engage in the grooves 36 of the first composite sheet 31. FIG.4 shows a lens of the invention 40 that includes a first composite sheet41 comprising a skived louvered web 42 and top and bottom clear layers43 and 44, and a second composite sheet 45 which is configured withlinear lens elements 46 and has linear septa 47 on which a layer ofadhesive 48 is applied to adhere the upper and lower composite sheetstogether.

Polymeric materials laminated together in forming a lens of theinvention should be thermoplastic, or at least thermosoftenable duringthe step of laminating the materials together. A preferred polymericmaterial is cellulose acetate butyrate; other useful materials includecellulose acetate, cellulose acetate propionate; methacrylates such aspolymethylmethacrylate; polycarbonates; polysulfones; and polyvinylchloride. Echelon lenses made of glass also benefit from the invention.

To maximize the improved contrast provided by lenses of the invention,the configured layer of a lens of the invention should be as thin aspossible, preferably less than 0.1 inch, more preferably less than 0.05inch, and even more preferably less than 0.03 inch, thick; and alouvered web should be in direct contact with the configured layer. Forlenses in which component parts are physically united other than bydirect lamination, as illustrated in FIGS. 3 and 4, the spacing betweenopposed configurations or between configurations and a louvered web, ispreferably less than 0.03 inch.

Moire patterns occur in their most noticeable form when superposedlouvers and echelon lens elements are slightly less than parallel. Twoarrangements of superposed configured layer and louvered sheet aregenerally used in preferred lenses of the invention to minimize moirepatterns: with the linear lens elements precisely parallel to andcoincident with the louvers; and with the linear lens elements arrangedat a significant angle to the louvers. The particular angle varies withsuch factors as the amount and uniformity of spacing between louvers andbetween echelon lens elements, but it usually is at least 10° and forpreferred effects is at least 20° or 30°. FIGS. 5 and 6 are enlarged topviews of louvered lenses of the invention in which the louvers andlinear lens elements are at 45° and 90°, respectively, to one another.In addition, moire patterns can be further minimized by using echelonelements of randomly varied width.

FIGS. 7 and 8 show a different flexible strip-type louvered echelon lensof the invention. This lens 50 comprises an internally louvered layer51, a bottom clear layer 52, and a configured layer 53, in which theconcentric annular configurations form a plurality of small annularechelon lenses 54. Generally the annular echelon lenses are analogs ofconcave or convex spherical or aspherical lenses of f/2 or less. A lensas shown in FIGS. 7 and 8 is particularly useful with matrix-typedisplays, with each annular lens 54 being associated with a particularcomponent of the matrix.

For use in miniature matrix displays the lenses generally have diametersless than about 1 inch. The result, especially with lenses less than 1/4or 1/2 inch in diameter, is that moire patterns are reduced to the pointthat they are generally not visible to the human eye. The reason forthis reduction is shown in FIGS. 9 and 10. FIG. 9 represents thejuxtaposition of an annular echelon lens element 55 from the edge of arelatively large-diameter annular echelon lens and a louver 56, whileFIG. 10 represent the juxtaposition of an annular echelon lens element57 from the edge of a small-diameter annular echelon lens and a louver58. As seen, the length of overlap between the annular echelon lenselement and louver is much larger for the structure represented in FIG.9 than for the structure represented in FIG. 10. Since it is thisoverlap that is responsible for moire patterns, the shortening of theoverlap reduces moire patterns. FIG. 7, because it is enlarged andbecause it is a drawing with lines of appreciable thickness, illustratesquite strong moire patterns.

As previously noted, the invention also provides large diameter louveredechelon lenses free of noticeable moire patterns but providing thetwo-axis or point focusing of an annular echelon lens. In such atwo-axis lens, two or more linear echelon lenses are superposed, withthe linear echelon lens elements generally orthogonal to one another. Aninternally louvered sheet is used together with such superposed linearechelon lenses so as to avoid noticeable moire patterns. For example,the lens of the invention 60 shown in FIG. 11 includes two superposedconfigured layers 61 and 62 each having linear echelon lens elements 63and 64, respectively, with a louvered web 65 between the two layers 61and 62. The linear echelon lens elements 63 and 64 are at 90° to oneanother and at 45° to the louvers 66 of the louvered web 65. In otherarrangements the louvers are parallel or at other angles to the linearechelon lens elements. More than two linear echelon lenses may besuperposed, to achieve particular focusing effects.

FIG. 12 shows a lens of the invention 70 which carries a layer ofspecularly reflective material, such as vapor-deposited aluminum, overan optically clear layer 72. Thus, light rays that enter through echelonlens elements 73 and pass between the louvers 74 are reflected andreturned by the reflective layer 71.

The ratio of the distance between the louvers of an internally louveredweb to the thickness of the web is regarded as the "aspect ratio" of theinternally louvered web. The lower the aspect ratio, the greater thecontrast, with little effect on normally incident controlled light. Forbest results, especially where two superposed configured layers areused, the louvered web has focused or fanned louvers (that is, thelouvers are arranged at varying angles that tend to parallel light raysto be transmitted between the louvers) which better accommodate lightrays that have been refracted by the configured layer first encounteredby the rays.

By "optically limiting louvers" it is meant that a light ray engagingthe louver is significantly altered, as by absorption or reflection.Generally the louvers are opaque, but they also may be transparent toparticular colors. In that way an internally louvered web or sheet actsas a filter, transmitting light having the color of the louvers, butabsorbing light that is not the color of the louvers.

Although the illustrated lenses have echelon lens elements exposed tothe air, it should be noted that the lens elements may also be internalin the lens structure. For example, a configured surface of a configuredlayer may be adhered to a polymeric material having an index ofrefraction that is significantly different (at least about 0.1 unitdifferent) from the index of refraction of the configured layer. Thatsignificantly different polymeric material may be the polymeric matrixof the louvered sheet or it may be a layer disposed between theconfigured layer and internally louvered sheet.

What is claimed is:
 1. A louvered echelon lens capable of transmittingimproved-contrast images comprising a unitary sheet that includes1. anoptically clear layer having a large-area surface configured as a linearechelon lens; and
 2. an internally louvered layer superposed in opticalconnection with said clear layer and comprising an optically clearpolymeric matrix and a set of thin light-absorbing linear louvers eachsupported within the matrix at an angle to the faces of the layer andaligned in spaced side-by-side relation so as to transmit light towardsaid configured surface while reducing light internally reflected withinsaid lens; said louvers extending in a direction other than a directionthat forms an angle of slightly greater than 0° up to 10° with thelinear echelon lens elements so as to minimize moire patterns that arisebecause of juxtaposition of echelon lens elements and louvers.
 2. Thelens defined in claim 1 wherein the angle is 0° and said louvers areparallel to the linear echelon lens elements.
 3. A lens of claim 1 inwhich the optically clear layer comprises the same polymeric material asthe polymeric matrix of the internally louvered layer.
 4. A lens ofclaim 1 in which the optically clear layer is thermally laminated indirect contact with the internally louvered layer.
 5. A lens of claim 1in which a layer of reflective material is incorporated in the lens soas to return light rays that enter through a large-area surface of thelens.
 6. A lens of claim 1 in which the louvers are at right angles tothe faces of the internally louvered layer.
 7. A lens of claim 1 inwhich the louvers are slanted at an angle other than 90° to the faces ofthe internally louvered layer.
 8. A lens of claim 1 in which at leastsome of the louvers are at different angles to the faces of theinternally louvered layer than others of the louvers.
 9. A lens of claim1 in which the louvers extend at an angle of greater than about 10° tothe linear echelon lens elements.
 10. A lens of claim 1 in which thelouvers extend at right angles to the linear echelon lens elements. 11.A lens of claim 1 in which the internally louvered layer is a web skivedfrom a layered billet and the optically clear layer is laminated indirect contact to said web.
 12. A lens of claim 1 which includes asecond optically clear layer of polymeric material disposed on the otherside of said internally louvered layer, said second optically clearlayer having a large-area surface configured as a linear echelon lens.13. A lens of claim 12 in which the linear echelon lens elements of thesecond optically clear layer are at approximately right angles to thelinear echelon lens elements of the first optically clear layer.
 14. Alens of claim 13 in which the louvers of the internally louvered layermake an angle of greater than 10° to the linear echelon lens elements ofboth optically clear layers.
 15. A thin flexible louvered echelon lenscapable of transmitting improved-contrast images comprising a unitaryflexible sheet that includes1. an optically clear layer having alarge-area surface configured as a linear echelon lens; and
 2. aninternally louvered layer fused in direct physical and opticalconnection over the whole interface with said clear layer and comprisingan optically clear polymeric matrix and a set of thin light-absorbinglinear louvers each supported within the matrix at an angle of about 90°to the faces of the layer and aligned in spaced side-by-side relation soas to transmit light toward said configured surface while reducing lightinternally reflected within said lens; said louvers extending in adirection other than a direction that forms an angle of slightly greaterthan 0° up to 10° with the linear echelon lens elements so as tominimize moire patterns that arise because of juxtaposition of echelonlens elements and louvers.
 16. A lens of claim 15 in which the louversextend at an angle of greater than 10° to the linear lens elements. 17.A lens of claim 15 in which the optically clear layer comprises the samepolymeric material as the polymeric matrix of the internally louveredsheet.
 18. A lens of claim 15 in which said optically clear layer isless than 0.03 inch thick.
 19. The lens defined in claim 15 wherein theangle is 0° and the louvers are parallel to the linear echelon lenselements.